1. Purpose
2. Scope
3. Reference
4. Responsibility
5. Work Methodology
5.1 Preparatory Work
5.1.1 Ventilation System
5.1.2 Manhole Opening, Inspection and Protection Method
5.1.3 Nozzle Inspection and Protection Method
5.1.4 Tray Pre-assembling Working Bed
5.1.5 Scaffolding Inside and Outside the Vessel
5.1.6 Davit Arm Load Test and Rope Pulley Assembly
5.2 Material Transportation and Control Method
5.3 Confined Space Control Method
5.3.1 Registration of Personnel and Personal Belonging
5.3.2 Personnel’s Outfit
5.3.3 Lighting Method
5.4 Column Internal Surface Cleaning Method
5.5 Internal Installation Method
5.5.1 Support Ring Installation and Level Reading Method
5.5.2 Tray Installation
5.5.3 Bolting Method
5.5.4 Welding Method on Vessel Internal Components
5.5.5 Leak Test Method
5.5.6 Box Up/ Vessel Final Closure
6. Manpower Organizational Chart
7. Equipment, Tools and Consumables
8. Inspection and Testing
9. Safety Instructions
10. Attachments
1.0 PURPOSE
The purpose of this Special Process Procedure for Pressure Vessel Internal Works is to ensure that the work activities such as material handling, installation and test & inspection shall be carried out safely, efficiently and in accordance with the project requirements.
2.0 SCOPE
The scope of works under this Special Process Procedure applies to installation of vessel internals covered under JAZAN REFINERY PROJECT scope of JGC/DEC with its main client SAUDI ARAMCO in Jizan, Kingdom of Saudi Arabia
3.0 REFERENCES
32-SAMMS-004 – Manufacture of Pressure Vessels
32-SAMMS-020 – Manufacture of Trays and Packing
SATIP-D-001-01 – Pressure Vessel Installation
SAIC-D-2009 Installation and Inspection of Trays & Packing in Vessels
SAES-D-001 Design Criteria for Pressure Vessels
SAES-C-001 Process Design of Trays and Packing
SAES-A-005 Safety Instruction Sheet
SAES-A-206 Positive Material Identification
SAES-W-010 Welding Requirements for Pressure Vessel
SASD-AD-036981 Tolerances for Pressure Vessel
API 686 Recommended Practices for Machinery Installation and Design
ASME Sec.VIII D1 & D2 Rules for Construction of Pressure Vessels
4.0 RESPONSIBILITY
Site Manager
Ensure full compliance by all Millwrights, Mechanical Foreman, Labor regarding execution of work and implementation of HSE procedure in accordance with project requirement and specifications. Confirm availability of all materials, tools, equipment and required personnel who will carry out the work.
Quality Control Inspector
Conduct inspection in accordance with this procedure. Monitor daily activities and verify compliance to ARAMCO Specifications. Prepares record and final acceptance documentation where required.
Construction Manager
a. Pre-mobilization Inspection and color coding for all tools and equipment used on site. Ensure that all safety requirements have been adequately addressed and the work is carried out in accordance with ARAMCO project safety procedures.
b. Ensure relevant documentation and certifications are submitted for operators, drivers, scaffolding and rigging.
Mechanical Supervisor
Prepare and submit method statement for JGC/DAEWOO/SAUDI ARAMCO review and approval. Provide latest revision of AFC drawings, procedures, material specifications standards and technical specifications.
Rigging Supervisor
To ensure that rigging and heavy lift activities are performed by SAUDI ARAMCO certified rigger in a safe and efficient manner. Rigging is engineered, performed and inspected to satisfy the customer’s requirements in accordance with the issued project drawings and specifications.
Safety Officer
Check the work areas and monitor from time to time in the implementation of safety procedure and assuring that all safety equipment and tools are present at site and in good working condition.
5.0 PROCEDURE WORK OF VESSEL INTERNAL
5.1 Preparatory Work
5.1.1 Ventilation System
Ventilation system shall be done using fans/blowers with sufficient capacity. Vacuum mode operation shall be preferred for ventilation, where required force ventilation to vessel top and allow fresh air from the bottom. Distance of the ventilation is also critical as it will obstruct access to the manhole, so careful planning shall be done prior to positioning of the fans/blowers in order to address
the air circulation inside the vessel. See attached sketch “A”.
5.1.2 Manhole Opening, Inspection and Protection Method
All manhole opening shall be done as per construction and safety procedure. Approved safety permit shall be procured prior to nitrogen gas removal. Inspection of manhole flange serration shall also be done. After inspection of manhole flange serration, put a rubber cover for protection. See attached sketch “B”. Bolts, nuts and gasket shall be kept for reinstatement.
5.1.3 Nozzle Inspection and Protection Method.
All equipment nozzle shall be inspected for it flange face serration. Should there be any unacceptable damage, it shall be corrected by re-facing it prior to vessel internal works. Appropriate cover and protection on its nozzle flanges face shall be done. Notice shall be given to Mechanical Department should there be any piping connections to be made. Blind fianges, bolts and nuts and gaskets of correct material shall be used to cover the nozzles of every equipment. Equipment nozzle shall never be use as support by any piping connections. Gaps shall be made between two connections (equipment nozzle and pipe flanges) until final box up of the vessels and piping works are done. See attached sketch “C”.
5.1.4 Tray Pre-assembling Working Bed
Tray pre-assembling working bed shall be of the same size as the diameter of the vessel involved. Materials to be use on top of the working bed shall be of the same materials of the vessel internal. Carefully pre-assembled the required vessel internals (level wise) and check precisely that all components are complete and of the correct position as if you installed it inside the vessel. Check also for its cleanliness and if contaminated with rust, clean thoroughly with approved cleaning method and solvent solution prior to
installation inside the vessel. After confirmation of material and cleanliness, carefully installed it piece by piece inside the vessel. See attached sketch “D’.
5.1.5 Scaffolding Inside and Outside the Vessel
Scaffolding inside and outside of the vessel shall be done by an approved Scaffolders only. Scaffolders shall install scaffolding with maximum effort not to damage the shell surface of the equipment most especially inside the vessel as it will result into scratches and will lead to rust development / contamination. All sharp corners and protruding metal ends of scaffolding shall be adequately covered with rubber.
Inside scaffolding shall be installed in such a way that enough working space is provided for installation of vessel internals. Outside scaffolding shall be installed with enough platform size in front of all manholes for worker’s access during working activities. Safety for all workers inside and outside the vessels shall be given much consideration in the scaffolding erection. A temporary cabinet shall
be placed (shall not obstruct manhole access) for safekeeping of personal belongings of workers inside the vessel.
5.1.6 Davit Arm Load Test and Rope Pulley Installation
Davit Arm and Rope Pulley shall be installed on top of the equipment for lifting vessel internal components. Safety shall be ensured prior its installation. Working load shall also be considered before its installation. It shall be installed in such a way that it will not obstruct the manhole access. Rope size shall be of enough size to carry the possible load weight of the vessel internal components. See attached sketch “E”.
5.2 Material Transportation and Control Method
5.2.1 A dedicated Material Controller shall take full control in the material transportation and storage of the vessel internal components. Procedure shall be made to ensure proper storage and issuance of the vessel internal components. Latest IFC drawings shall be made available on the material container for perusal. Should there be any discrepancy between the IFC drawings and packing list, it shall be reported immediately to the Discipline Manager for proper disposition.
5.3 Confined Space Control Method
5.3.1 Registration of Personnel and Personal Belonging Control
A confined space entry permit shall be procured prior to start of any internal works. Complete gas testing shall be made by a competent safety personnel. A log sheet shall be made available at the entrance of the manhole for registration of all personnel who will enter the confined space work place. A dedicated trained and competent watchman shall position in front of the manhole access and will continue to observe the activity inside the vessel at all times. All personal belongings of the workers inside the vessel shall be deposited to the temporary cabinet located outside the entrance of the vessel equipment.
5.3.2 Personnel’s Outfit
All workers inside the vessel equipment shall wear cover all, full body harness (without the line yard) and shoes cover before entering the inside working area.
5.3.3 Lighting Method
An explosion proof with 12 volt illumination capacity lights shall be made available inside the vessel equipment during working and inspection time. Lightings shall be placed at the area most necessary for workers and inspectors.
5.4 Column Internal Surface Cleaning Method
5.4.1 Cleaning of internal surface of vessel equipment shall be done prior to installation of internal trays. It shall be done by wiping out dust and other foreign particles with a clean and cotton made rags. Any visible rust contamination shall be abraded with sand paper and wipe with cotton made rags or by other means of cleaning method approved by ARAMCO.
5.5 Internal Installation Method
5.5.1 Support Ring Installation and Level Reading Method
Support ring installation shall be done on a level wise stage. Install the support ring precisely on the internal of vessel equipment. Check for the orientation of the support ring. The support ring levelness shall be checked by using a 12 mm Ø manometer hose level. Once it is levelled, tighten the bolt to stabilize its position. It is now possible to start Tray Installation.
5.5.2 Tray Installation
Tray installation shall be done on a level wise stage starting from the lowest level. Components shall be ensured its cleanliness and completeness before installation. Clean the portion of inside shell of dust and other foreign particles. From the pre-assembled parts on the ground, start to install it on the internal of vessels. Carefully assemble and place the components the same way it was on the ground. Start bolting the components to ensure stability. Once the assembly of tray on the first level is completed, clean the portion of the internal surface of shell where the second level of tray will be assembled. Place a sheet of non combustible material on the completed first level tray to ensure its cleanliness of dust and other foreign particles. Continue doing the same procedure until
completion of tray installation. Always check and double check the tray identification and orientation to ensure continuity of installation work inside the equipment vessel. Ensure that gaps and spacing of individual trays are correct and is based on the latest AFC drawing.
5.5.3 Bolting Method
Once the assembly of individual trays are completed, bolts shall be tighten using a calibrated torque wrench. Prior to using torque wrench, bolts shall be initially tightened by using hands/fingers. Ensure that no force fit on bolts shall happen that it will damage the bolt thread once being torque by wrench on the final stage of bolt tightening.
5.5.4 Welding Method on Vessel Internal Components
Welding method on vessel internal components shall be done with approved vendor WPS or WPS approved by the COMPANY. Safety procedure shall be taken into consideration as always. Ensure that slags and fumes shall be removed by safety means during the course of the welding activity. Ensure that all cables and materials for welding shall not contaminate the assembled trays installed
inside the vessels. Outmost care shall be observed especially on the falling melted slags. Adequate fire blanket must be provided in the entire duration of the welding activity.
5.5.5 Leak Test Method
Once the entire installation of vessel internals trays are completed, final inspection shall be made to ensure completeness of the installation. After inspection and acceptance of the responsible personnel, leak testing of assembled trays will commence. Third party certified demineralized water shall be use for the leak test. Chloride content of the demineralized water shall not exceed 50ppm. The water level shall not drop by more than 25mm after 1 hour and 15 minutes of testing to pass the acceptance criteria for leak test. All trays shall be thoroughly dried after the leak testing.
5.5.6 Box Up/ Vessel Final Closure
After completion of the inside vessel tray installation and leak testing, final inspection shall be made by concerned parties. Once complete inspections and acceptance were done, immediately close the manholes. Apply the required torque value on the bolts of manhole flange. Purge the equipment with nitrogen until required pressure. Notice shall be given to Mechanical Department should
final piping connections will be done.
7.0 EQUIPMENT, TOOLS AND CONSUMABLES
7.1 Crane for special lift
7 .2 Slings and soft tag lines
7.3 Davit arm and rope pulley assembly
7.4 Manometer hose
7.5 Feeler gauges and calipers
7.6 Calibrated torque wrench
7. 7 Calibrated gas detectors
7.8 Cover all and shoe cover
7.9 Fans/blowers of sufficient capacity
7.10 Lightings of sufficient illumination
7.11 Welding materials.
8.0 INSPECTION AND TESTING
8.1 All inspections shall be done in accordance to SATIP-D-001-01.
8.2 Leak testing shall be done in compliance to SATR-D-2004.
8.3 Installation of tray assembly shall be done in compliance to SAIC-D-2009.
8.4 Visual inspection shall be made for the flatness of tray floor. Correct use of clamping devices, etc. are to be observed. Bolt tightening inspection shall be done using calibrated torque wrench with valid calibration certificate.
8.5 All assembled tray components shall be free of dust and foreign particles prior to box up/final closure.
8.6 Nitrogen purging for preservation purposes shall commence after box up/ final closure.
8. 7 Required pressure of .35 bar (5 psi) minimum or vendor’s recommendation shall be applied.
9.0 SAFETY INSTRUCTIONS
9.1 Make sure that all necessary work permits are issued.
9.2 Check all lifting equipment prior to commencing lifting activities.
9.3 Stay away from any suspended load/falling objects.
9.4 Wear full body harness when working at elevated platform and confined space.
9.5 Install safety nets when necessary.
9.6 Ensure that barricades and warning signs are properly installed.
9.7 Ensure that there are no hazardous or combustible gases present in the work area.
9.8 Install adequate illumination when working at dark areas. Tool Box Talk and discuss work methodology prior to commencement of work.
9.9 Implement and monitor safety instruction on site.
9.10 Conduct visual inspection for mobile equipment and provide daily checklist.
9.11 Hand and power tools shall be inspected prior to use.
9.12 Conduct visual inspection for mobile equipment and provide daily checklist.
9.13 Rigging and lifting safety materials shall be inspected by the competent person prior to use.
9.14 For CSE, work permit is required, provide training certificate for hole watch/stand-by man and time-in/time-out sheet shall be signed by entrants.
9.15 Joint inspection shall be conducted by work permit issuer and work permit receiver to eliminate the hazard and to isolate the work area.
9.16 Conduct gas test and provide air mover fan.
9.17 Housekeeping should be done upon completion of work.
10.0 ATTACHMENTS
10.2 “A” (Ventilation System)
Note:
I. Ventilation shall be done as per set up no. 01.
2. Ventilation shall be place alternately on manholes, say if the work is on MH 02, the fan/blower is place on MH 01, and so on.
3. All manholes shall have its own platform set up as shown in MH 03, MH 05 and MH 07.
4. All scaffolding set ups on manholes are typical for all vessel equipment with internal works.
10.3 “B” (Manhole Opening Protection)
10.4 “C” (Nozzle Protection)
10.5 ‘D(Tray Working Bed Assembly)
10.6 ‘E (Davit Arm and Pulley Assembly)
